Method and apparatus for gantry system mobility

ABSTRACT

An assembly includes an attachment arm having an axle extending from a first end of the attachment arm. The attachment arm of the detachable wheel assembly further includes a securing portion forming a second end of the attachment arm, the securing portion of the attachment arm including a pin positioned to extend above a first frame member of a gantry truss and to secure the first frame member between the pin and a portion of the attachment arm. The attachment arm also includes a frame support corresponding to a second frame member of the gantry truss such that the frame support supports the second frame member when the assembly is secured to the gantry truss, and the assembly includes a wheel rotatably attached to the axle of the attachment arm.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of and claims priority to U.S. patentapplication Ser. No. 17/192,694, filed Mar. 4, 2021, and entitled“METHOD AND APPARATUS FOR GANTRY SYSTEM MOBILITY” the disclosure ofwhich is hereby incorporated by reference in its entirety for allpurposes

TECHNICAL FIELD

The present disclosure relates to a method and apparatus that providesmobility for a three-dimensional additive gantry system. Morespecifically, the present disclosure relates to a detachable wheelassembly that is securable to a gantry truss of a three-dimensionaladditive gantry system such that the gantry system is movable on thewheel assembly.

BACKGROUND

Three-dimensional (“3D”) additive systems are used in a variety ofapplications to form various types of parts, systems, or structures. 3Dadditive systems and processes enable creation of parts that can belighter, stronger, or more complex than parts formed by traditionalmanufacturing processes. Furthermore, 3D additive systems can form partsin a more continuous manner than traditional manufacturing processes.

As products formed by the 3D additive system increase in size, the 3Dadditive systems used to form such products can also increase in size.For example, 3D additive systems have been used to fabricate buildingsor other structures and/or structural components. Such 3D additivesystems require support structures to which 3D additive components canbe secured and on which the 3D additive components are moveable during a3D additive manufacturing process.

An example 3D additive construction system is described in U.S. PatentPub. No. 2020/0282593 (hereinafter referred to as the ′593 reference).In particular, the ′593 reference describes a construction system thatcan utilize additive manufacturing processes to produce 3D additiveproducts or structures. The ′593 reference describes a constructionsystem that is moved to and from a construction site via a truck-pulledtrailer. For example, the ′593 reference describes loading and unloadingthe construction system to and from a flatbed trailer by rolling theconstruction system on rollers that engage with ramps that extend fromthe trailer to the construction site. However, such rollers requireloading and offloading the construction system on or off a trailer tomove the construction system. The ′593 reference further describes anadditional caster wheel that can be included on a support assembly ofthe construction system. Such a caster wheel allows the constructionsystem to be moved on a foundation, warehouse floor, or trailer bed.However, the caster wheel requires the use of tools to attach or detachthe caster wheel to or from the construction system. Furthermore, acaster wheel does not provide rugged mobility for the constructionsystem if the construction system is used on an uneven or undevelopedsurface (e.g., dirt, gravel, rock, grass, etc.). As such, the mobilitysystem (e.g., the rollers and the caster wheels) described in the ′593reference are not easily attached or removed and provide poor mobilitysolutions when implement on uneven or undeveloped surfaces.

Example embodiments of the present disclosure are directed towardovercoming the deficiencies described above.

SUMMARY

An example assembly includes an attachment arm having an axle extendingfrom a first end of the attachment arm. The attachment arm of thedetachable wheel assembly further includes a securing portion forming asecond end of the attachment arm, the securing portion of the attachmentarm including a pin positioned to extend above a first frame member of agantry truss and to secure the first frame member between the pin and aportion of the attachment arm. The attachment arm also includes a framesupport corresponding to a second frame member of the gantry truss suchthat the frame support supports the second frame member when theassembly is secured to the gantry truss, and the assembly includes awheel rotatably attached to the axle of the attachment arm.

An additive manufacturing system includes a gantry frame assemblyincluding a gantry truss and a gantry bridge assembly including atrolley movable along a lateral truss of the gantry bridge assembly. Thesystem further includes a gantry carriage assembly movably secured tothe gantry frame assembly and configured to support at least a portionof the gantry bridge assembly and a wheel assembly removably attachableto the gantry truss. The wheel assembly includes an axle forming a firstend of the wheel assembly, a wheel rotatably attached to the axle, asecuring portion forming a second end of the wheel assembly, thesecuring portion including a pin configured to secure a first framemember of the gantry truss between the pin and a portion of the wheelassembly, and a frame support mating with a second frame member of thegantry truss such that the frame support supports the second framemember of the gantry truss when the wheel assembly is removably attachedto the gantry truss.

In a further example, a method of includes adjusting one or more jacksto raise a gantry frame assembly of a gantry system, wherein the one ormore jacks are attached to at least one gantry truss of the gantry frameassembly. The method further includes coupling a wheel assembly to theat least one gantry truss at a location along the gantry frame assemblyat a balance point of the gantry system and moving the gantry systemfrom a first location on a support surface to a second location on thesupport surface spaced from the first location by rolling the gantrysystem on the wheel assemblies.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of an example three-dimensional additivesystem in accordance with an example of the present disclosure.

FIG. 2 is a perspective view of an example wheel assembly attached to athree-dimensional additive system in accordance with an example of thepresent disclosure.

FIG. 3 is a perspective view of an example wheel assembly of athree-dimensional additive system in accordance with an example of thepresent disclosure.

FIG. 4 is a front view of an example wheel assembly secured to a gantrytruss of a three-dimensional additive system in accordance with anexample of the present disclosure.

FIG. 5 is a flowchart illustrating a method of positioning athree-dimensional additive system using an example wheel assembly inaccordance with an example of the present disclosure.

DETAILED DESCRIPTION

This disclosure generally relates to a three-dimensional (“3D”) additivesystem (referred to herein as “the system”). The system described hereinis used to construct various types of structures, portions ofstructure(s), or other products utilizing additive manufacturingprocesses. Such additive manufacturing processes may enable constructionof structures and/or portions thereof more economically and/or quickerwhen compared with traditional construction processes of like structuresand/or portions thereof. Typically, additive manufacturing processesdeposit an extrudable building material in vertically stacked layers toform the structure and/or portions thereof. As such, the system requiresa support structure that is capable of supporting a gantry bridge thatmoves along the support structure during an additive manufacturingprocess. In implementations, the support structure facilitatesrelatively free movement of a supply hose, e.g., in x-, y-, andz-directions, to accomplish the construction.

FIG. 1 depicts a perspective view of an example 3D additive system 100(referred to herein as “the system 100”). As mentioned previously, thesystem 100 is used to construct various types of structures, portions ofstructure(s), or other products utilizing an additive manufacturingprocess. For example, in an additive manufacturing process, anextrudable material is conveyed through a conduit 102 to be deposited,delivered, or otherwise conveyed in a desired location. The conduit 102guides deposition of the extrudable material such that the extrudablematerial is vertically stacked in layers to form the structure and/orportions thereof. In some examples, the conduit 102 includes hoses,pipes, or other types of conduit that are configured to convey theextrudable material (or components thereof) from a source to the desireddeposition location to a desired deposition site (e.g., a constructionsite). Furthermore, the conduit 102 includes a nozzle 104 located at anend of the conduit 102. The nozzle 104 may be configured to at leastpartially control a flow rate of the extrudable material during anadditive manufacturing process.

The source (not shown) of the extrudable material includes a mixer,hopper, tank, vessel, etc. that is configured to prepare, store, and/orcontain a volume of extrudable material. Furthermore, the system 100includes one or more water containers 103. The water containers 105store a volume of water (and/or other liquid) that may be used during anadditive manufacturing process. In some examples, water may be added tothe extrudable material while the extrudable material is pumped duringthe additive manufacturing process. Additionally, and/or alternatively,water (and/or other liquid) from the water containers 103 may be mixedwith a raw material (e.g. cement) to form the extrudable material andthe extrudable material is then pumped through the conduit 102 anddeposited. In some examples, the extrudable material may comprise acement mixture. Additionally, and/or alternatively, the extrudablematerial may include other types of extrudable materials that may beused in an additive manufacturing process to form a structure and/orportions thereof.

As shown in FIG. 1 , the conduit 102 may be attached to a boom 106 thatis configured to convey the conduit 102 such that the conduit 102 avoidscontact with portions of structure that has previously been extruded (orotherwise formed). For example, the boom 106 may facilitate movement ofthe conduit 102 in a vertical and/or horizontal direction such that thenozzle 104 of the conduit 102 may be positioned in a desired locationfor depositing the extrudable material, while the remainder of theconduit 102 avoids contact with obstacles (such as portions of astructure or other product that was previously formed). The boom 106 ofthe system 100 is adjustable in various directions to allow the nozzle104 of the conduit 102 to be positioned in any location within thesystem 100. Additionally, the boom 106 may allow the conduit 102 andnozzle 104 to be positioned outside of the system 100 in order to clean,repair, and/or replace the conduit 102 and/or the nozzle 104.

In some examples, a portion of the conduit 102 that is proximate thenozzle 104 is secured to an end of a gantry truss 108. The gantry truss108 extends in a substantially vertical direction (e.g., the z-directionin FIG. 1 ) and may be secured by or coupled to a trolley 110. Thetrolley 110 is configured to adjust a position of the gantry truss 108,thereby positioning the conduit 102 and nozzle 104 in a desiredlocation. For example, the trolley 110 includes guide wheels and one ormore motors that are configured to move the gantry truss 108 in one ormore directions sequentially or simultaneously. For example, the trolley110 is configured to adjust a position of the gantry truss 108 in avertical direction (e.g., a direction along the Z-axis illustrated inFIG. 1 ). As a vertical position of the gantry truss 108 is adjusted bythe trolley 110 (via the motor and guide wheels), the position of theconduit 102 and nozzle 104 are also adjusted vertically. Furthermore,the trolley 110 is configured to adjust a position of the gantry truss108 in a lateral direction (e.g., along the Y-axis illustrated in FIG. 1). For example, the guide wheels and one or more motors are configuredto move the trolley 110 along a horizontal truss 112 of a gantry bridgeassembly 114 (referred to herein as “the gantry bridge 114”). As thetrolley 110 moves along the horizontal truss 112, the gantry truss 108secured by the trolley 110 is also translated along the X-axis. As such,a position of the conduit 102 and the nozzle 104 is adjusted by thetrolley 110 that is secured to and movable along the gantry bridge 114.

The system 100 further includes a gantry frame assembly 116 (referred toherein as “the gantry frame 116”). The gantry frame 116 comprisesmultiple components coupled to form a generally horizontal,substantially U-shaped frame. More specifically, the gantry frame 116 isillustrated as including gantry trusses 118 that form a first length 120of the gantry frame 116. In some examples, the first length 120 of thegantry frame 116 may be formed from a single gantry truss 118 or thefirst length 120 may be formed by multiple gantry trusses 118 that arecoupled (e.g., fastened) to each other. The gantry frame 116 furtherincludes gantry trusses 118 that form a second length 122 of the gantryframe 116 spaced from the first length 120. The second length 122 of thegantry frame 116 may be formed by a single gantry truss 118 or thesecond length 122 may be formed by multiple gantry trusses 118 that arecoupled (e.g., fastened) to each other. In some examples, the firstlength 120 of the gantry frame 116 extends in a direction that issubstantially parallel to a direction of extension of the second length122 of the gantry frame 116. Furthermore, the first length 120 and thesecond length 122 may be substantially equal such that the first length120 and the second length 122 are within a predetermined tolerance(e.g., +/−6 inches) of each other.

Furthermore, the first length 120 of the gantry frame 116 is spacedapart from the second length 122 of the gantry frame 116 by a distancethat forms a width of the gantry frame 116. For example, the gantryframe 116 includes one or more additional gantry trusses 118 that form afirst width 126 of the gantry frame 116. The first width 126 of thegantry frame 116 may be formed by a single of the gantry trusses 118 ormultiple gantry trusses 118 that are connected (or fastened) to eachother. Furthermore, the first width 126 of the gantry frame 116 isconnected to ends of the first length 120 and the second length 122 ofthe gantry frame 116, thereby connecting the first length 120 and thesecond length 122 of the gantry frame 116. Accordingly, the gantry frame116 includes a plurality of the gantry trusses 118 comprising the firstlength 120, the second length 122 and the first width 126, making thegantry frame 116 substantially U-shaped. As will be appreciated, duringoperation of the system 100, a building or other structure made usingthe 3D additive processes described herein may be formed within afootprint of the gantry frame 116.

In some examples, the gantry frame 116 may further include instances ofthe gantry trusses 118 that form a second width (not shown in FIG. 1 )of the gantry frame 116. The second width of the gantry frame 116 islocated at an end of the first length 120 and the second length 122 thatis opposite the first width 126. When provided, the gantry trusses 118forming the second width configure the gantry frame 116 as asubstantially rectangular frame. In some examples, the first width 126and/or the second width may be removed once a structure or portionthereof is completed in order to remove the system 100 from a locationof the completed structure.

The system 100 may include one or more jacks 128 attached to and locatedat various locations on the gantry frame 116. The jacks 128 may beadjustable to alter a vertical position of the gantry frame 116. Forexample, when one or more jacks 128 are adjusted, at least a portion ofthe gantry frame 116 moves in a direction relative to the Z-axis. Insome examples, the jacks 128 may include wheels that contact a surfaceon which the system 100 rests when the jacks 128 are adjusted, e.g., toextend the wheels past a base of the jacks 128. Thus, a position of thesystem 100 may be adjusted via the wheels of the jacks 128. The wheelsof the jacks 128 are shown and described further with respect to FIG. 2. While FIG. 1 depicts the system 100 as having four jacks (e.g.,128(1), 128(2), 128(3), and 128(4)) located at multiple positions on thegantry frame 116, the system 100 may include more than or fewer thanfour jacks 128 located at similar or different locations on the gantryframe 116.

In some examples, the horizontal truss 112, the gantry truss 108 securedby the trolley, and the gantry trusses 118 of the gantry frame 116 mayinclude a same or similar type of gantry truss. For example, thehorizontal truss 112, the gantry truss 108 secured by the trolley 110and the gantry trusses 118 may be triangular shaped trusses (or“triangular trusses”). The triangular trusses may include threelongitudinal members that are connected via one or more horizontalmembers, diagonal members, etc. Alternatively, in some examples, thegantry trusses used in the system 100 may include a different shape orconfiguration. These and other components of the gantry trusses 112,108, and 118 are shown and described further herein with respect to FIG.2 .

As mentioned previously, the system 100 includes a gantry bridge 114. Asshown in FIG. 1 , the gantry bridge 114 is at least partially supportedby the gantry frame 116. For example, the gantry bridge 114 includes thehorizontal truss 112 that spans a distance between and is coupled onopposite ends to a first vertical truss 130 and a second vertical truss132. In some examples, the first vertical truss 130 is at leastpartially supported by (and is coupled to) the first length 120 of thegantry frame 116 and the second vertical truss 132 is at least partiallysupported by (and is coupled to) the second length 122 of the gantryframe 116. For example, the first vertical truss 130 may be attached toa first carriage assembly 134 that is movably secured to the firstlength 120 of the gantry frame 116. The first carriage assembly 134 maybe attached to the first length 120 of the gantry frame 116 via guidewheels that allow the first carriage assembly 134 to be movable alongthe first length 120 of the gantry frame 116. Similarly, the secondvertical truss 132 may be attached to a second carriage assembly 136that is movably secured to the second length 122 of the gantry frame116. The second carriage assembly 136 may be attached to the secondlength 122 of the gantry frame 116 via guide wheels that allow thesecond carriage assembly 136 to be movable along the second length 122of the gantry frame 116. The first carriage assembly 134 and the secondcarriage assembly 136 may include guide wheels that are configured toreduce wear on components of the system 100, mitigate uplift of thecarriage assemblies 134 and 136, mitigate potential debris buildup,among other potential benefits.

The system 100 may also include a controller 138 that is configured tocontrol various operations of the system 100. For example, thecontroller 138 controls motors included in the system 100 that areconfigured to move various components (e.g., carriage assemblies) of thesystem 100 during an additive manufacturing process. The controller 138may also control a pump or pump system (not shown) that is configured topump the extrudable material through the conduit 102 during the additivemanufacturing process. The controller 138 may control these and otherfunctions of the system 100.

In some examples, the controller 138 includes, for example, amicrocontroller, memory (e.g., RAM), storage (e.g., EEPROM or Flash)configured to perform the described functions of the controller 138. Thecontroller 138 controls at least a portion of the operations of thesystem 100 including operation of the motors (which are shown anddescribed further herein below). Instead of, or in addition to, anengine control module (ECM)/engine control unit (ECU) the controller 138may include a general computer microprocessor configured to executecomputer program instructions (e.g., an application) stored in memory140 to perform the disclosed functions of the controller 138. Asmentioned, the controller 138 includes a memory, a secondary storagedevice, processor(s), and/or any other computing components for runningan application. Various other circuits may be associated with controller138 such as power supply circuitry, signal conditioning circuitry, orsolenoid driver circuitry. In some examples, the controller 138 and/or aportion of components of the controller 138 may be located remotely fromthe system 100 and may be communicatively coupled to the system 100. Forexample, the controller 138 may include any suitable assembly and/ordevice that receives and/or transmits signals to other devices. Thecontroller 138 may include one or more processors 142 executes machinereadable instructions provided from the memory 140 that enable thefunctionality of the processors 142 and/or the controller 138

The system 100 further includes one or more wheel assemblies 144 thatare attachable to the gantry frame 116. The wheel assemblies 144 mayprovide mobility to the system 100 such that a position of the system100 may be adjusted by rolling (or otherwise moving) the system 100 onthe wheel assemblies 144 relative to a work surface/support surface onwhich the system 100 is disposed. Furthermore, the wheel assemblies 144may allow the system 100 to be moved in any direction along the X-axisor the Y-axis and/or a combination thereof. In some examples, the wheelassemblies 144 may be removable from the system 100. For example, thewheel assemblies 144 may be attached to the system 100 in order toposition the system 100 in a desired location (such as a constructionsite or other location). Once the system 100 is moved into the desiredlocation, the wheel assemblies 144 may be removed. Furthermore, once thewheel assemblies 144 are removed, the jacks 128 may be adjusted to levelthe system 100 for an additive manufacturing process. Conversely, oncean additive manufacturing process (or a portion thereof) is completed,the jacks 128 may be adjusted to raise the gantry frame 116 to asufficient height in order to attach the wheel assemblies 144 to thegantry frame 116. Once the wheel assemblies 144 are attached, the jacks128 may be adjusted to lower the gantry frame 116 such that the system100 rests, at least partially, on the wheel assemblies 144. As such, thesystem 100 may be balanced and rolled on the wheel assemblies 144 inorder to adjust a position of the system 100 and/or to remove the system100 from a construction site.

In some examples, the wheel assemblies 144 may be attached to the gantryframe 116 at a location that corresponds with balance points 146(1) and146(2) along the gantry frame 116 of the system 100 (or substantiallyproximate the balance point). Each balance point 146(1) and 146(2) isdefined by a location along the first length 120 and the second length122 of the gantry frame 116 that is bisected by an axis 148 (shown bydashed line 148 in FIG. 1 ) extending along the Y-axis such that aweight of the system 100 is equal on either side of the axis 148. Thatis to say, the axis 148 bisects the gantry frame 116 at balance points146(1) and 146(2) where the wheel assemblies 144 are attached,respectively, such that a weight of the system 100 on a first side 150of the axis 148 is equal to a weight of the system 100 on a second side152 of the axis 148. It should be noted, that the position of the wheelassemblies 144 shown in FIG. 1 may or may not correspond with thebalance points 146(1) and 14(2) of the system 100. Furthermore, alocation of the balance points 146(1) and 146(2) will vary along theX-axis as the gantry bridge 114 is moved along the X-axis. Furthermore,a location of the balance points 146(1) and 146(2) will vary based onthe number of gantry trusses 118 that form the gantry frame 116 andbased on the number of gantry trusses 118 that are disposed on eitherside of the gantry bridge 114 along the gantry frame.

In some examples, the gantry bridge 114 may be positioned proximate anend 154 of the system 100 and the wheel assemblies 144 may be attachedto the gantry frame 116 at a location that corresponds with the balancepoints 146(1) and 146(2) of the system 100 based on the gantry bridge114 being positioned at an end of the gantry frame 116. By placing thewheel assemblies 144 at a position that corresponds with the balancepoints 146(1) and 146(2) of the system 100, a position of the system 100may be adjusted with reduced turning effort when compared to wheels thatare placed in other locations of a gantry system. As such, a position ofthe system 100 may be easily adjusted by one or more users absent use ofmachinery. Additionally, and/or alternatively, the position of thesystem 100 may be adjusted using machinery even when the wheelassemblies 144 are attached to the gantry frame 116 at a location thatcorresponds with the balance points 146(1) and 146(2) of the system 100.

In some examples, the system 100 may include a first wheel assembly144(1) attached to a gantry truss 118 that forms at least a portion ofthe first length 120 of the gantry frame 116 and a second wheel assembly144(2) attached to a gantry truss 118 that forms at least a portion ofthe second length 122 of the gantry frame 116. In such an example, thefirst wheel assembly 144(1) and the second wheel assembly 144(2) may bepositioned on the first length 120 and the second length 122 of thegantry frame 116 at corresponding locations along the Y-axis. Asmentioned previously, such a location may correspond with a balancepoints 146(1) and 146(2) of the system 100. For example, when attachedto the system 100, the first wheel assembly 144(1) and the second wheelassembly 144(2) may raise the gantry frame 116 from a surface on whichthe first wheel assembly 144(1) and the second wheel assembly 144(2)rest such that the system 100 is movable on the first wheel assembly144(1) and the second wheel assembly 144(2). It should be noted that thegantry bridge 114 and/or the wheel assemblies 144(1) and 144(2) may bepositioned along the gantry frame 116 such that the gantry frame 116 maybe balanced on the wheel assemblies 144(1) and 144(2) in order to movethe system 100 on the wheels assemblies 144(1) and 144(2). These andother features of the wheel assemblies 144 are shown and describedfurther herein with respect to FIGS. 2-4 .

FIG. 2 is a perspective view of the system 100 having a wheel assembly144 attached to the gantry frame 116 of the system 100. While only thefirst carriage assembly 134 is shown FIG. 2 , it is to be understoodthat the second carriage assembly 136 may include substantially similarfeatures as the first carriage assembly 136. For ease of explanation,the first carriage assembly 134, as shown and described in FIG. 2 , willbe referred to as “the carriage assembly 134”.

As described previously, the system 100 includes one or more jacks 128attached to the gantry frame 116. FIG. 2 depicts a single jack of theone or more jacks 128 attached to the gantry frame 116 at anintersection between gantry trusses 118. The jacks 128 include a baseframe 202 that may rest on a surface 203 when a wheel 204 of the jacks128 is retracted such that the wheel 204 does not extend past a bottom205 of the base frame 202. Alternatively, the jacks 128 may include afoot plate instead of a wheel 204. The wheel 204 of the jacks 128 mayinclude a caster or other type of wheel. Furthermore, the jacks 128 mayinclude a crank 206 that, when rotated, adjusts a vertical position ofthe wheel 204. In some examples, the jacks 128 may include a threadedshaft that acts against corresponding threads in a housing of thethreaded shaft or acts against a plate of the base frame. Additionally,and/or alternatively, the jacks 128 may be pneumatic or hydraulic. Byadjusting the vertical position of the wheel 204, a vertical position ofthe gantry frame 116 may also be adjusted. A such, the gantry frame 116may be leveled by adjusting one or more jacks 128 at various positionsalong the gantry frame. Furthermore, when the jack 128 is adjusted suchthat the wheel 204 extends past the base frame 202, the gantry frame 116may be raised and may be removed from contacting a surface on which thewheel 204 and/or the gantry frame 116 rests. When all jacks 128 of thesystem 100 are adjusted such that the wheels 204 extend past the baseframe 202, a position of the system 100 may be adjusted. However, whenresting on wheels 204 of the jacks 128, adjustments of the position ofthe system 100 may be relatively minor (e.g., moving the system a fewfeet).

As mentioned previously, the system 100 also includes wheel assemblies144 that are attachable to gantry trusses 118 of the gantry frame 116 inorder to move the system 100. In some examples, smaller adjustments(e.g., adjustments of a few feet) of a position of the system 100 may becompleted using the wheels 204 of the jacks 128. Additionally, largeradjustments (e.g., adjustments more than a few feet and/or moving thesystem 100 to or from a construction site) may be completed using thewheel assemblies 144. The wheel assemblies may include wheels 208 thatare capable of traversing rough terrain (e.g., dirt, gravel, grass,etc.). For example, the wheels 208 of the wheel assemblies 144 mayinclude a tire 210 mounted on the wheels 208. The wheel 208 of the wheelassemblies 144 is rotatably mounted on an axle 212 of the wheelassemblies 144. For example, the wheel 208 may include bearings thatallow the wheel 208 to be secured to the axle 212 while being rotatablearound the axle 212.

In some examples, a motor 214 may be coupled to the carriage assembly134. The motor 214 includes an electric motor that communicativelycoupled to the controller 128 such that the motor 214 is controlled bythe controller 138 of the system 100. For example, the controller 138sends one or more instructions to the motor 214 that causes the motor tomove the carriage assembly 134 along the gantry frame 116. The motor 214may include wheels, gears, pulleys, other mechanisms that are configuredto engage with a drive system of the carriage assembly 136 to move thecarriage assembly 134 along the gantry frame 116. In some examples, eachcarriage assembly (i.e., the first carriage assembly 134 and the secondcarriage assembly 136) may include a motor 214 that is configured tomove the carriage assemblies 134 and 136 along the gantry frame 116.

FIG. 3 is a perspective view of the wheel assembly 144. As shown in FIG.3 , the wheel assembly 144 is removed from the gantry frame 116 of thesystem 100. The wheel assembly 144 may include an attachment arm 302 towhich the wheel 208 is mounted and by which the wheel assembly 144 ismounted to a gantry truss 118 of the gantry frame 116. The attachmentarm 302 (and components thereof) may be formed from metal to provideadequate strength to the wheel assembly 144. In some examples, the axles212 of the wheel assembly 144 extends from a first end 304 of theattachment arm 302. As mentioned previously, the wheel assembly 144includes a wheel 208 rotatably mounted to the axle 212 of the wheelassembly 144 via bearings or other component allowing the wheel 208 tobe secured to and rotate independently of the axle 212.

The wheel assembly 144 further includes a securing portion 306 forming asecond end 308 of the attachment arm 302. The securing portion 306 ofthe attachment arm 302 includes a pin 310 positioned to extend above aframe member of a gantry truss and secure the frame member between thepin 310 and a lateral portion 312 of the attachment arm 302. In someexamples, the pin is a spring-loaded pin and may allow the wheelassembly 144 to be attached to the gantry frame 116 without requiringuse of tools. In some examples, the securing portion 306 of theattachment arm 302 includes a substantially vertical tab 307 having anaperture therein through which the pin 310 is insertable. The lateralportion 312 (or cradle portion) of the attachment arm 302 extendsbetween the securing portion and a frame support 314 of the attachmentarm 302. When the wheel assembly 144 is attached to a gantry truss, thelateral portion 312 of the wheel assembly 144 supports at least aportion of the gantry truss. For example, a frame member of gantry trussmay rest on the lateral portion 312 of the wheel assembly 144 such thatthe lateral portion supports the gantry truss. Furthermore, anotherframe member of the gantry truss may be supported by the frame support314 of the attachment arm 302. The frame support 314 may be shaped tocorrespond with a frame member of the gantry truss such that the framesupport 314 supports the frame member when the wheel assembly 144 issecured to the gantry truss. For example, as shown in FIG. 3 , the framesupport 314 is formed by a partial cylinder having an opening 316 atleast partially facing the securing portion 306 of the attachment arm302. In some examples, the securing portion 306 of the wheel assembly144 is attached to a frame member of a gantry truss and the wheelassembly 144 is then rotated until another frame member of the gantrytruss rests at least partially within the frame support 314.

FIG. 4 is a front view of the wheel assembly 144 secured to a gantrytruss 118 of the gantry frame 116. As described previously, the wheelassembly 144 include a securing portion 306 configured to secure a framemember 402 of the gantry truss 118 between the pin 310 of the securingportion 306 and the lateral portion 312 of the wheel assembly 144. Thesecuring portion 306 may be curved or otherwise shaped to correspondwith a shape of the frame member 402. The wheel assembly 144 alsoincludes the frame support 314 that is shaped to correspond with a framemember 404 of the gantry truss 118. The cylindrical shape of the framesupport 314 may prevent movement of the frame member 404 once the wheelassembly 144 is secured to the gantry truss 118 and the gantry trussrests at least partially on the attachment arm 302 of the wheel assembly144. In some examples, the longitudinal members of the gantry truss 118are connected by helical members 406 of the gantry truss 118. The spacerplate 406 may support at least a portion of the gantry truss 118.Furthermore, in some examples, the securing portion 306 and the framesupport 314 are offset vertically from the axle 212 such that thesecuring portion 306 and the frame support 314 are located below theaxle 212 vertically.

The wheel assemblies 144 described herein may be easily attached to agantry truss 118 of the gantry frame 116 of the system 100. In someexamples, attaching the wheel assembly 144 to the gantry truss 118 maybe completed without requiring the use of tools. For example, one ormore users adjust one or more of the jacks 128 to raise at least aportion of the gantry frame 116 of the surface 203. The wheel assemblies144 are then coupled to the gantry truss 118 by clamping a frame member402 of the gantry truss 118 between the pin 310 and the lateral portion312 of the wheel assembly 144. Meanwhile, another frame member 404 ofthe gantry truss 118 rests on and is supported by the frame support 314of the wheel assembly 144. The wheel assemblies 144 may be positionedalong the gantry frame 116 at balance points 146(1) and 146(2) such thata weight of the system 100 is equal across an axis 148 that bisects thegantry frame 116. The wheel assemblies 144 and the location of the wheelassemblies 144 on the gantry frame 116 allow the system 100 to be easilymoved around a construction site. Furthermore, by placing the wheelassemblies 144 at the respective balance points 146(1) and 146(2), thesystem 100 is able to be lifted and rolled by one or more users. Forexample, a force required to lift and roll the system 100 on the wheelassemblies 144 located at the balance points 146(1) and 146(2) may bewithin a limit for human ergonomics and/or safety requirements.

FIG. 5 is a flowchart illustrating a method 500 of positioning thesystem 100 using the wheel assemblies 144. The method 500 may beperformed by one or more human users. However, at least a portion (e.g.,step 506) of the method 500 may be executed and/or otherwise performedby the controller 138. The method 500 may include different and/oradditional steps, and may be performed in a different order thandescribed herein.

At 502, the method 500 includes positioning the gantry bridge 114 at alocation on the gantry frame 116. In some examples, the controller 138sends instructions to one or more motors 214 coupled to the carriageassemblies 134 and 136 that are configured to move the carriageassemblies 134 and 136 along the gantry frame 116. The instructions maycause the motors 214 to move the gantry bridge 114 such that the gantrybridge 114 is positioned proximate an end 154 of the gantry frame 116prior to moving the system 100. By positioning the gantry bridge 114proximate the end 154 of the gantry frame 116, the balance points 146(1)and 146(2) of the system 100 may be proximate the end 154 of the gantryframe 116 rather than the middle thereof. Moving the balance points146(1) and 146(2) of the system 100 towards an end of the gantry frame116 may reduce effort required to move (and/or turn) the system 100.

At 504, the method 500 includes adjusting one or more jacks 128 of thesystem 100 to alter a vertical position of the gantry frame 116 of thesystem. As mentioned previously, the jacks 128 include cranks 206 that,when rotated, adjust a vertical position of the wheel 204 of the jacks128. Since the jacks 128 are attached to the gantry frame 116, adjustinga vertical position of the wheel 204 of the jacks 128 may also adjust avertical position (or height) of the gantry frame 116.

At 506, the method 500 includes determining a location of the balancepoints 146(1) and 146(2) of the system 100. As mentioned previously, thelocation of the balance points 146(1) and 146(2) of the system 100 aredefined by locations along the first length 120 and the second length122 of the gantry frame 116 that are bisected by an axis 148. In someexamples, the controller 138 may determine the balance points 146(1) and146(2) of the system 100 based on a position of the gantry bridge 114and/or by accessing known metrics and/or parameters of the system 100stored in memory 140 of the controller 138. Furthermore, the location ofthe balance points 146(1) and 146(2) may be an approximate location(e.g., within a predetermined tolerance) of the balance points 146(1)and 146(2). Still further, human users may determine the location of thebalance points 146(1) and 146(2) of the system 100 based at least inpart on the position of the gantry bridge 114, dimensions of the gantryframe 116, or other parameters.

At 508, the method 500 includes coupling wheel assemblies 144 to thegantry frame 116 at the balance points 146(1) and 146(2) on the gantryframe 116. Securing the wheel assemblies 144 to the gantry frame 116 mayinclude latching the securing portion 306 to a first frame member viathe pin 310 and rotating the wheel assembly 144 such that a second framemember rests in the frame support 314. In some examples, at least twowheel assemblies 144 are attached to the gantry frame 116 atsubstantially similar locations on respective lengths of the gantryframe 116. In such an example, the system 100 may be moved by tippingthe system 100 such that the system 100 is balanced on the wheelassemblies 144 and is movable thereon. Alternatively, more than two(e.g., four) wheel assemblies 144 may be attached to the system 100 andthe system 100 may be rolled on the wheel assemblies 144.

At 510, the method 500 includes removing a number of gantry trusses 118from the gantry frame 116. Step 510 may occur after a structure has beenformed by an additive manufacturing process so as to allow the system100 to be moved from around the structure without damaging thestructure. For example, if the gantry frame 116 forms an enclosed frame,an end of the frame may be removed such that the system 100 is movablearound the structure. As such, the system 100 may be moved when thegantry frame 116 forms a U-shaped frame, as shown in FIG. 1 . Removingthe number of gantry trusses 118 may include decoupling (e.g., removingbolts or other fasteners) gantry trusses 118 from one another.

At 512, the method 500 includes moving the gantry system 100. Asmentioned previously, in examples where the system includes two wheelassemblies 144 attached to the gantry frame 116, the system is moved bytipping the system 100 such that the system 100 is balanced on the wheelassemblies 144 and is movable thereon. Alternatively, if four (or more)wheel assemblies 144 are attached to the gantry frame 116, the system100 may be rolled without having to tip the system to balance the systemon the wheel assemblies 144. In some examples, balancing the system 100on the wheel assemblies 144 may be within ergonomic and safetyrequirements for a human user (or multiple human users) to complete. Insuch examples, one or more human users may easily move and steer thesystem 100 on the wheel assemblies 144.

INDUSTRIAL APPLICABILITY

The present disclosure provides an improved 3D additive manufacturingsystem configured to construct various types of structures, portions ofstructure(s), or other products utilizing additive manufacturingprocesses. The system described herein includes one or more wheelassemblies that are detachable from a gantry frame of the system. Thewheel assemblies are positioned along the gantry frame at respectivelocations that allow one or more humans users to easily manipulate aposition of the system. For instance, as noted above, an example system100 includes a gantry frame assembly 116, a gantry bridge assembly 114,and a gantry carriage assembly 136 secured to a gantry truss 118 of thegantry frame assembly 116. The system 100 includes detachable wheelassemblies 144 that are attached to the gantry frame assembly 116 of thesystem 100. The detachable wheel assemblies 144 are disposed a locationalong the gantry frame assembly 116 that corresponds with a balancepoints 146(1) and 146(2) of the system 100.

Due to example configurations described herein, the system 100 is easilymoveable by one or more human operators. For example, wheel assemblies144 described herein are attached to a gantry truss 118 of the gantryframe 116 of the system 100 without requiring the use of tools to attachthe wheel assemblies 144 to the gantry frame 116. Furthermore, the wheelassemblies 144 may be positioned along the gantry frame 116 at balancepoints 146(1) and 146(2) such that a weight of the system 100 is equalacross an axis 148 that bisects the gantry frame 116. The wheelassemblies 144 and the location of the wheel assemblies 144 on thegantry frame 116 allow the system 100 to be easily moved around aconstruction site. Furthermore, by placing the wheel assemblies 144 atthe respective balance points 146(1) and 146(2), the system 100 is ableto be lifted and rolled by one or more users. For example, a forcerequired to lift and roll the system 100 on the wheel assemblies 144located at the balance points 146(1) and 146(2) may be within a limitfor human ergonomics and/or safety requirements.

While aspects of the present disclosure have been particularly shown anddescribed with reference to the embodiments above, it will be understoodby those skilled in the art that various additional embodiments may becontemplated by the modification of the disclosed machines, systems andmethods without departing from the spirit and scope of what isdisclosed. Such embodiments should be understood to fall within thescope of the present disclosure as determined based upon the claims andany equivalents thereof.

What is claimed is:
 1. An additive manufacturing system, comprising: agantry frame assembly comprising: at least one first gantry trussforming a first length; at least one second gantry truss substantiallyparallel to the at least one first gantry truss and forming a secondlength; and at least one third gantry truss extending from the at leastone first gantry truss to the at least one second gantry truss, whereinthe at least one first gantry truss, the at least one second gantrytruss, and the at least one third gantry truss form a U-shaped framedefining a portion of a footprint; a gantry bridge assembly extendingabove the gantry frame assembly and including a lateral truss extendingin a direction generally parallel to the at least one third gantrytruss; a gantry carriage assembly configured to move the gantry bridgeassembly along at least one of the at least one first gantry truss orthe at least one second gantry truss; a vertical truss coupled to thelateral truss and moveable relative to the lateral truss; a conduitcoupled to the vertical truss and configured to deposit an extrudablematerial to manufacture a structure in the footprint; and a wheelassembly coupled to the gantry frame assembly to facilitate movement ofthe gantry frame.
 2. The additive manufacturing system of claim 1,wherein the at least one third gantry truss extends from a first end ofthe at least one first gantry truss to a first end of the at least onesecond gantry truss, the additive manufacturing system furthercomprising: at least one fourth gantry truss extending from a second endof the at least one first gantry truss to a second end of the at leastone second gantry truss, wherein the at least one first gantry truss,the at least one second gantry truss, the at least one third gantrytruss, and the at least one fourth gantry truss define the footprint. 3.The additive manufacturing system of claim 2, wherein the at least onefourth gantry truss is removably coupled to at least one of the secondend of the at least one first gantry truss or the second end of the atleast one second gantry truss.
 4. The additive manufacturing system ofclaim 3, wherein: the at least one fourth gantry truss is coupled to thesecond end of the at least one first gantry truss and to the second endof the at least one second gantry truss during deposition of theextrudable material to manufacture the structure in the footprint; andthe at least one fourth gantry truss is decoupled from the at least oneof the second end of the at least one first gantry truss or the secondend of the at least one second gantry truss to provide an openingproximate the second end of the at least one first gantry truss and thesecond end of the at least one second gantry truss to facilitate removalof the gantry frame assembly from the structure via the opening.
 5. Theadditive manufacturing system of claim 4, wherein the wheel assemblyfacilitates removal of the gantry frame assembly from the structure. 6.The additive manufacturing system of claim 1, wherein the wheel assemblycomprises: an attachment arm including: an axle extending from a firstend of the attachment arm, a securing portion forming a second end ofthe attachment arm, the securing portion of the attachment arm includinga pin positioned to extend above a first frame member of the at leastone first gantry truss and to secure the first frame member between thepin and a portion of the attachment arm, and a frame supportcorresponding to a second frame member of the at least one first gantrytruss such that the frame support supports the second frame member whenthe wheel assembly is secured to the at least one first gantry truss;and a wheel rotatably attached to the axle of the attachment arm.
 7. Theadditive manufacturing system of claim 6, wherein the frame support isformed by a partial cylinder having an opening facing the securingportion of the attachment arm.
 8. The additive manufacturing system ofclaim 6, wherein the wheel assembly further comprising a cradle portionextending between the securing portion and the frame support andconfigured to support at least a portion of the at least one gantrytruss, the cradle portion formed by a laterally extending portion of theattachment arm.
 9. The additive manufacturing system of claim 6, whereinthe securing portion and the frame support are offset vertically fromthe axle such that the securing portion and the frame support arelocated below the axle vertically.
 10. The additive manufacturing systemof claim 6, wherein the securing portion includes a vertical tab with anaperture through which the pin is insertable.
 11. A method of additivemanufacturing, comprising: providing an additive manufacturing systemincluding: a gantry frame assembly having: at least one first gantrytruss forming a first length, at least one second gantry trusssubstantially parallel to the at least one first gantry truss andforming a second length, at least one third gantry truss extendingbetween the at least one first gantry truss and the at least one secondgantry truss, and at least one fourth gantry truss extending between andbeing coupled to the at least one first gantry truss and the at least onsecond gantry truss at a position spaced from the at least one thirdgantry truss, wherein the at least one first gantry truss, the at leastone second gantry truss, the at least one third gantry truss, and the atleast one fourth gantry truss form a frame defining a footprint, agantry bridge assembly extending above the gantry frame assembly andincluding a lateral truss extending in a direction generally parallel tothe at least one third gantry truss, a conduit coupled to the gantrybridge assembly, and a wheel assembly associated the gantry frameassembly; depositing, via the conduit, an extrudable material to form astructure in the footprint; uncoupling, at least in part in response toforming the structure in the footprint, the at least one fourth gantrytruss from at least one of the at least one first gantry truss or the atleast one second gantry truss, the uncoupling of the at least one fourthgantry truss providing an opening between the at least one first gantrytruss and the at least one second gantry truss; and moving, via a wheelassociated with the wheel assembly, the additive manufacturing systemrelative to the structure, the moving causing the structure to passthrough the opening.
 12. The method of claim 11, further comprising:raising, via one or more jacks, the gantry frame assembly; and at leastone of coupling or decoupling the wheel assembly to the gantry frameassembly.
 13. The method of claim 12, wherein the wheel assembly iscoupled to or decoupled from a bottom portion of the at least one firstgantry truss or the at least one second gantry truss.
 14. The method ofclaim 11, wherein: the structure is formed at a first location, and themoving the additive manufacturing system comprises moving the additivemanufacturing system to a second location spaced from the firstlocation, the method further comprising: re-coupling the at least onefourth gantry truss to the at least one of the at least one first gantrytruss or the at least one second gantry truss; and depositing, via theconduit, the extrudable material to form a second structure in thefootprint at the second location.
 15. The method of claim 11, wherein:the gantry frame assembly further comprises a trolley configured to morerelative to the gantry bridge assembly; and the conduit is coupled tothe trolley, the method further comprising: moving, during thedepositing the extrudable material, the trolley to reposition theconduit.
 16. The method of claim 11, further comprising: adjusting oneor more jacks to raise the gantry frame assembly, wherein the one ormore jacks are attached to at least one of the at least one first gantrytruss or the at least one second gantry truss; and coupling the wheelassembly to the at least one of the at least one first gantry truss orthe at least one second gantry truss at a location along the gantryframe assembly at a balance point, wherein the moving the additivemanufacturing system comprises moving from a first location on a supportsurface to a second location on the support surface spaced from thefirst location by rolling the gantry frame assembly on the wheelassembly.
 17. The method of claim 16, further comprising positioning thegantry bridge assembly at an end of the gantry frame assembly prior tosecuring the wheel assembly.
 18. The method of claim 11, wherein theuncoupling comprising removing the at least one fourth gantry truss inorder to remove an end of the gantry frame assembly.
 19. The method ofclaim 11, wherein the wheel assembly includes: an axle having the wheelrotatably attached thereto, the axle forming a first end of the wheelassembly; a securing portion forming a second end of the wheel assembly,the securing portion including a pin configured to secure a first framemember of the at least one first gantry truss between the pin and aportion of the wheel assembly; and a frame support shaped to correspondwith a second frame member of the gantry truss such that the framesupport supports the second frame member of the at least one firstgantry truss when the wheel assembly is secured to the gantry truss. 20.The method of claim 19, wherein the frame support is formed from apartial cylinder having an opening that faces the securing portion ofthe wheel assembly.